EP1390201B1 - Procede et appareil automatique d'elimination de zones dechets - Google Patents
Procede et appareil automatique d'elimination de zones dechets Download PDFInfo
- Publication number
- EP1390201B1 EP1390201B1 EP02750598A EP02750598A EP1390201B1 EP 1390201 B1 EP1390201 B1 EP 1390201B1 EP 02750598 A EP02750598 A EP 02750598A EP 02750598 A EP02750598 A EP 02750598A EP 1390201 B1 EP1390201 B1 EP 1390201B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- laminate
- area
- carrier
- waste
- adhesive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/18—Means for removing cut-out material or waste
- B26D7/1836—Means for removing cut-out material or waste by pulling out
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
- B08B7/0028—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by adhesive surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/18—Means for removing cut-out material or waste
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D1/00—Multiple-step processes for making flat articles ; Making flat articles
- B31D1/02—Multiple-step processes for making flat articles ; Making flat articles the articles being labels or tags
- B31D1/026—Cutting or perforating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/10—Removing layers, or parts of layers, mechanically or chemically
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/06—Interconnection of layers permitting easy separation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
- B44C3/005—Removing selectively parts of at least the upper layer of a multi-layer article
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10S156/934—Apparatus having delaminating means adapted for delaminating a specified article
- Y10S156/935—Delaminating means in preparation for post consumer recycling
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1062—Prior to assembly
- Y10T156/107—Punching and bonding pressure application by punch
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/108—Flash, trim or excess removal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/1317—Means feeding plural workpieces to be joined
- Y10T156/1322—Severing before bonding or assembling of parts
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/19—Delaminating means
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/19—Delaminating means
- Y10T156/1906—Delaminating means responsive to feed or shape at delamination
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/19—Delaminating means
- Y10T156/1994—Means for delaminating from release surface
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/16—Two dimensionally sectional layer
- Y10T428/163—Next to unitary web or sheet of equal or greater extent
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24826—Spot bonds connect components
Definitions
- This invention is related generally to decal laminate technology, such as is involved in the preparation of one or more decals (e.g., "graphic areas” or “product areas") which are formed as part of a removable layer of a laminate for later removal and application onto various surfaces. More particularly, the invention relates to the field involving prior removal of waste portions of removable laminate layers, leaving the removable decal in place on the laminate.
- decal laminate technology such as is involved in the preparation of one or more decals (e.g., "graphic areas” or “product areas”) which are formed as part of a removable layer of a laminate for later removal and application onto various surfaces. More particularly, the invention relates to the field involving prior removal of waste portions of removable laminate layers, leaving the removable decal in place on the laminate.
- decals are graphics-image-bearing portions (sometimes referred to herein as "product areas,” whether or not they have graphics images thereon) of a removable layer (sometimes referred to herein as a "face layer") of a laminate.
- Each such decal laminate typically includes the face layer and a backing layer (or “liner"), the face layer being removably secured to the backing layer by an adhesive.
- the adhesive is preferential to the face layer, and is used, after removal of the product area(s) from the backing layer, for the adhesive attachment of the product area(s) of the face layer onto the surface intended to be covered - for decorative, signage or any of a multitude of other purposes.
- Sheet-weeding is typically carried out by nimble-fingered workers who delicately lift and peel away unused portions of the image-bearing face layer of a decal laminate. This is tedious and time-consuming work. Progress has been made toward automating the sheet-weeding process; despite such efforts, there remains a need for an improved automatic waste-area removal method and apparatus.
- the computer-controlled systems of the Logan patents use complex adhesive materials including microspheres or microcapsules which, when broken by force application, release strong adhesive to allow an overlay sheet to engage and remove portions of a sheet.
- adhesives can be very expensive, and force-activation can be problematic and difficult in high-speed operations.
- the Reed disclosure involves an embossing of areas to be removed in order to weaken their adhesive attachment to the base layer and facilitate removal.
- embossing tends to be a step which, among other things, may be unacceptable for removal of intricate waste areas or patterns around irregularly shaped decals or product areas.
- the Sasaki disclosure involves removal of an overlayer after a separation is caused by radiation treatment of a radiation-responsive composition. This system is complex and believed not to be suitable for many high-speed production operations.
- US 6,106,645 describes a method and apparatus for making a graphic product from a layer of sheet material on a carrier sheet using a bonding web with an adhesive which can be thermally activated.
- a bonding web which covers the entire sheet material
- the bonding web is heated at predetermined areas whereby the adhesive is activated and bonds with the adjacent sheet material. All areas of the sheet material bonded in this way are afterwards stripped from the sheet material as waste.
- US 4,869,767 discloses an improved method for placing single or multiple patterned layers of conductive material on a substrate.
- a metalized foil is joined with a waste web having a shaped adhesive print.
- the printing of the adhesive onto the waste web is done by a conventional printing apparatus e.g. using the high quality offset lithography method. After printing the pattern of adhesive to the waste web it is attached to a conductive layer.
- US 4, 869, 767 discloses also an apparatus for removing at least one waste area of a face layer from a laminate composed of a backing layer with the face layer adhering thereto, to leave at least one product area of the face layer in place on the backing layer, said apparatus comprising a support for the laminate, an adhesive applicator, a carrier-surface member having a carrier surface positioned to receive the laminate with the laminate adhering thereto, and a separator adjacent to the carrier surface to separate the laminate from the carrier surface with the waste areas remaining on the carrier surface.
- Another object of this invention is to provide a sheet-weeder and sheet-weeding method which can operate at high speeds.
- Another object is to provide a sheet-weeder which can operate with little or no detrimental effects to the product areas remaining on the laminate.
- Another object of the invention is to provide a sheet-weeding method which more reliably removes all or nearly all of the waste areas of the face layer from the backing layer while more reliably not removing all or nearly all of the product areas.
- Another object of the invention is to provide a sheet-weeding which allows reliable removal of waste areas of the face layer from the backing layer around delicate products areas.
- Still another object of the invention is to provide a sheet-weeder which is simple, efficient and cost-effective.
- Yet another object of the invention is to provide an improved method and apparatus for removal of select areas of less-than-all layers of a laminate which are useful in a wide variety of contexts and applications.
- the invention is a method and apparatus for removing waste area(s) of a face layer sheet from a laminate composed of a backing layer with the face layer removably adhering thereto, while leaving at least one product area of the face layer in place on the backing layer according to claims 1 and 20, respectively.
- the carrier-surface member is a carrier sheet - most preferably a carrier web.
- the adhering step, in which the laminate is adhered to the carrier web or other carrier sheet, such combination is sometimes referred to herein as a "carrier lamination".
- carrier lamination is discarded with the waste area(s) remaining on it.
- Suitable carrier web materials include unused newsprint. Embodiments using a carrier web facilitate continuous or nearly continuous sheet-weeding.
- the process of separating the laminate from the carrier web while leaving the waste areas on the carrier web involves peeling the carrier web away from the laminate.
- the separating step include the step of pulling the carrier web over a separator edge in tension to initiate separation of the laminate from the carrier web.
- the carrier-surface member is preferably in the form of a carrier web; however, in some embodiments it can be in the form of a fairly large cylindrical roller - sufficient to accommodate various operations therearound.
- the carrier web may be a long continuous two-ended web, such as the newsprint mentioned above, or may be an endless web each portion of which is used and reused.
- the method of this invention preferably includes, after the step of separating the laminate from the carrier surface with the waste areas thereon, the further step of removing the waste areas from the carrier surface and discarding the waste areas, thereby clearing the carrier surface for reuse.
- the adhesive is applied adjacent to the product area(s). It is preferred that the adhesive applicator apply a quick-drying liquid adhesive, doing so by shooting the adhesive onto the specific locations of the waste area(s) without applicator contact with the waste area(s).
- Certain preferred embodiments in which a carrier web is used include: unrolling a portion of the carrier web from a roll; performing the laminating of a laminate to the unrolled portion of the carrier web; separating the laminate from the unrolled portion; and thereafter rolling up the carrier web with the waste area(s) thereon.
- the web is moving in a direction along its length at least during the laminating and separating steps.
- the product and waste area(s) each have at least one leading-edge portion and at least one trailing-edge portion (see definitions infra ) , some of the leading-edge portion(s) of the waste area(s) being adjacent to trailing-edge portions of the product areas.
- the adhesive is applied to the leading-edge portion(s) of the waste areas.
- the precise locations of adhesive application are controlled by a computer. Precise locations are determined by what is best to affect separation of waste areas while leaving product areas fully intact on the backing layer.
- the apparatus of this invention includes: a support for the laminate; an adhesive applicator adjacent to the supported laminate; an actuator associated with the applicator; a controller for the actuator to cause application of an adhesive to the waste area(s); a carrier-surface having a carrier surface positioned to receive the waste area(s); a carrier-surface having a carrier surface positioned to receive the laminate with the laminate adhering thereto; and a separator adjacent to the carrier surface to separate the laminate from the carrier surface with the waste area(s) remaining on the carrier surface.
- Certain embodiments of such apparatus also include a stripper for removing the waste area(s) from the carrier surface after the separation has been accomplished. This allows the carrier surface, which is preferably endless, to be reused, and in some cases enhances the continuous nature of the operation.
- Certain preferred forms of the apparatus of this invention include: a work surface on which to receive the laminate; at least one adhesive applicator mounted adjacent to the work surface; an actuator associated with the applicator(s); an actuator controller to cause application of an adhesive to predetermined portions of the waste area(s); a laminator beside the work surface including a supply of carrier web oriented for temporary lamination with the laminate using the applied adhesive; and a delaminator positioned to receive the carrier lamination and delaminate the laminate therefrom with the waste area(s) adhering to the carrier web.
- the carrier-surface member is a carrier web.
- the separator include a separator edge positioned so that the carrier web passes under tension over the edge to initiate separation of the laminate from the carrier web.
- the face layer of the laminate has a plurality of registration marks at and about the product area(s) which are used for locating those areas of the laminate to which adhesive is to be applied.
- the apparatus includes a controller (e.g., computer) programmed with information on the product area(s) and the waste area(s) and a sensor mounted adjacent to the work surface and capable of sensing locations of the registration marks and transmitting such information to the controller.
- the applicator(s) is/are actuated in response to the information about the locations of the registration marks sensed by the sensor and the information on the product area(s) and the waste area(s).
- the laminates for which the method and apparatus of this invention facilitate sheet-weeding operations can be in various forms.
- the laminates can be in the form of discrete sheets, either large or small, or a laminate may be in the form of a lengthy continuous sheet (web) which extends from a supply roll to a take-up roll.
- the laminates to be weeded may have a large number of product areas on it, in a great variety of shapes and sizes, and a great number of waste areas in a variety of shapes and sizes.
- a lengthy continuous laminate web may have one or more rows of identically-shaped product areas such as labels or the like.
- this invention is a method for removing sub-areas of a face layer from a laminate composed of a backing layer with the sub-areas removably adhering thereto over less than all of the backing layer, and the invention involves: applying an adhesive oh portions of the sub-areas; temporarily adhering the laminate to a carrier sheet using the adhesive; and separating the sub-areas from the backing layer by peeling them off with the carrier sheet.
- one waste area has a leading edge portion with a leading edge that includes a lead part and at least one trailing lateral part
- the separating step includes (1) separating the waste area (with the carrier surface, e.g., a carrier sheet in web or other form) from the backing layer along the lead part before the trailing lateral part(s) are separated from the backing layer, thereby creating a chord line spanning the lead part, (2) continuing the separating step until the chord line substantially spans the leading edge portion, and (3) thereafter completing the separating step.
- the leading edge portion have at least one starter tab along the lead part of the leading edge, the starter tab extending in the direction opposite the weeding direction and having a width less than about 10% of the width of the leading edge portion.
- the leading edge is convex.
- such convex leading edge is a substantially circular arc having a radius greater than half the width of the leading edge portion.
- Such arc can be very gentle; even if the radius is substantially greater than the width of the leading edge portion to the point that the arc is nearly a straight line, waste area removal is substantially facilitated.
- the waste area in which a product area has a delicate leading edge portion, includes one trailing edge portion adjacent to the delicate leading edge portion, such trailing edge portion having a force-modifying slit therein which surrounds the delicate leading edge portion and has ends on opposite sides thereof.
- the ends of the force-modifying slit are downstream of the delicate leading edge portion.
- the force-modifying slit is arcuate; the slit may be substantially circular. It is highly preferred that the ends of the force-modifying slit be downstream of the delicate leading edge portion.
- a particularly delicate product areas is surrounded by a temporary product area such that the temporary product area is removed from the backing layer at some time following the completion of the automatic weeding process.
- liquid adhesive refers to a liquid adhesive which, when applied by the applicator, flows in its liquid state easily enough to be applied with a jet applicator or sprayer but which, when applied to the waste areas of the face layer, dries rapidly enough such that it acts properly as an adhesive when it is contacted by the carrier-surface member.
- weeding direction refers to the direction in which the weeding progresses along a sheet or roll of materia. More specifically, it refers to the direction of motion of the line along which separation of waste areas from the backing layer, occurs. Accordingly, the weeding direction proceeds from “upstream” positions to “downstream” positions.
- leading edge portion and “trailing edge portion” pertain, e.g., to portions of areas of the face layer (i.e., portions of the product areas/or portions of the waste areas) in embodiments of this invention in which the carrier surface (e.g., the surface of a carrier web) is moving during the adhering and separating (or “laminating” and “delaminating") steps of the sheet-weeding process.
- a leading edge portion of a waste area is a part thereof which is (1) immediately adjacent to and following a product area as determined along lines parallel to the weeding direction or (2) is immediately adjacent to a leading edge of the laminate if such leading edge is part of a waste area of the laminate.
- a trailing edge portion of a product area is a part of thereof which is immediately adjacent to and ahead of a waste area as determined along lines parallel to the weeding direction.
- leading edge portion and trailing edge portion refer to the order of portions undergoing separation - with a “leading portion” always being encountered before a “trailing portion.”
- leading edge refers to the line along the farthest upstream boundary of the leading edge portion of such waste area.
- width refers to a dimensional measurement taken across the waste area in a direction substantially perpendicular to the weeding direction.
- chord line refers to the line along which separation of a waste area from the backing layer takes place, with the length of the chord line being equal to the length of the continuous portion of the waste area being separated from the backing layer.
- force ratio refers to the ratio of "adhering forces” to "pulling forces” on a portion of face layer.
- adheredhering forces include both (1) the holding force of the adhesive layer (between the face layer and the backing layer of the laminate material) and (2) any additional forces from the surrounding face layer (i.e., the force exerted on the portion of waste area by the surrounding product area from incomplete slitting of the face layer and/or the adhesive layer and/or from rejoining of portions of the adhesive layer on either side of the slit) which are holding the portion of the waste area in place, and "pulling forces” are adhesive forces between the waste areas and the carrier surface from the adhesive applied the waste areas.
- adhering forces are the force applied by the adhesive layer between the face layer and the backing layer of the laminate material
- pulseling forces include both (1) the force exerted on the portion of the product area by the surrounding waste area being removed from around the portion of the product area (i.e., similar to the forces from surrounding waste area described above) and (2) any small forces which might occur from the contact of the carrier surface with the portion of the product area.
- delicate leading edge portion refers to a portion of the product area for which the force ratio is approximately one or less than one and which has a dimension along the weeding direction.
- delicate leading edge portions of product areas are susceptible to unwanted separation from the backing layer unless the force ratio is raised.
- delicate leading edge portions of product areas include pointed leading edge portions such as the points of a star or small shapes such as letters.
- force-modifying slit refers to cuts made in the trailing edge portion of a waste area adjacent to and surrounding a delicate leading edge portion of a product area to change the force ratio of the portion of the product area.
- starter tab refers to small areas of waste area added to leading edge portions of waste area and extending in the upstream direction from the leading edge portion in order to change the force ratio of the leading edge portion of waste area, thereby enabling initiation of the separation of the waste area from the backing layer.
- particularly delicate product area refers to entire product areas which are characterized by a low force ratio.
- temporary product area refers to a small area of waste area which is not separated from around particularly delicate product areas and which are separated from the backing layer by hand after completion of the automatic weeding process.
- the laminate 50 a discrete sheet made up of multiple layers, including face layer sheet 52, adhesive layer 54, and backing layer 56.
- Fig. 1 and 3-7 also include illustrations of laminate sheet or sheets 50 with face layer 52, adhesive layer 54, and backing layer 56.
- face layer 52 has been slit (severed), with the slit lines isolating product areas 58 from waste areas 60.
- Product areas 58 are shown in simple form; in many cases, the shapes of product areas may be very complex or intricate, and may have islands of waste areas within them. When waste areas 60 are weeded from laminate sheet 50, products areas 58 remain on backing layer 56 for their eventual intended use.
- Fig. 2 further illustrates the leading and trailing edges of both product areas 58 and waste areas 60. If motion of laminate sheet 50 is assumed to be left to right as indicated in Fig. 2 , then the location of a leading edge 68 of waste area 60 is as indicated. In similar fashion, a trailing edge 70 of a product area 58, a leading edge 64 of a product area 58, and a trailing edge 66 of a waste area 60 are indicated in Fig. 2 .
- Fig. 2 further illustrates discrete locations 62 of adhesive 72 applied to waste areas 60 of face layer 52.
- Adhesive 72 can be one of various quick-drying adhesives which are known in the art. Acceptable choices would be known to those skilled in the art and who are made aware of this invention.
- One group of adhesives which are useful are permanent waterborne acrylic pressure-sensitive adhesives available from ICI Americas Inc., New York, New York.
- adhesive applicator 76 is positioned over discrete locations 62 on face layer 52 and applies adhesive 72 to discrete locations 62. As shown in Fig. 3 and 4 , adhesive applicator 76 does not make contact with face layer 52 of laminate sheet 50, but applies adhesive 72 by rapidly and accurately shooting small quantities of adhesive 72 in the form of droplets or spray 74. Applicators suitable for use as adhesive applicator 76, such as a jet or sprayer, are known in the art. Fig. 4 further illustrates a work surface 12 adjacent to applicator 76 for receiving laminate sheets 50. Fig. 6 and 7 , described further below, illustrate alternative devices for adhesive application.
- Fig. 1 which illustrates a much larger portion of inventive sheet-weeding apparatus 10, the embodiment shown is of the type which incorporates a carrier-surface member in the form of a carrier web 14 and in which carrier web 14 is moving in apparatus 10 in a direction along its length.
- laminate sheets 50 and carrier web 14 are moving from right to left through apparatus 10.
- laminate sheet 50 moves from right to left, laminate sheet 50 is at first received and supported by support by work surface 12.
- Adhesive applicator 76 is mounted adjacent to work surface 12 on an actuator apparatus 36.
- Actuator apparatus 36 includes an actuator frame 38 and an actuator bar 40, and is configured and arranged such that adhesive applicator 76 can be moved back and forth along actuator bar 40 and actuator bar 40 can be moved back and forth along actuator frame 38, all under computer control as referred to below. In this way, any point on face layer 52 is available to receive adhesive 72.
- a plurality of applicators can be associated with one or more actuator apparatuses.
- a sensor 78 is also adjacent to work surface 12 and is mounted such that it can be moved back and forth along actuator bar 40 along with adhesive applicator 76.
- Sensor 78 is responsive to registration marks 44.
- Sensor 78, actuator apparatus 36, and applicator 76 are connected to controller 46 through controller cable 48.
- Controller 46 is a computer programmed with information on product areas 58 and waste areas 60 such that the position of product areas 58 and waste areas 60 on work surface 12 enable actuator 36 to respond to controller 46 to move applicator 76 to the desired locations on face layer 52 and apply the precise amount of adhesive 72 to face layer 52.
- Carrier web 14 is unrolled from a carrier web supply roll 16 and temporarily laminated with laminate sheet 50 by passing through a laminator, which includes a face layer laminator roller 18 and a backing layer laminator roller 20.
- the temporary lamination formed by laminator rollers 18 and 20 is held together by applied adhesive 72, and is referred to as a carrier lamination 24.
- Carrier lamination 24 is in tension as carrier lamination 24 is received by a delaminator 26, which includes a separator edge 28 and a retaining bar 30. Separator edge 28 has a tightly-rounded leading edge 32 which is shaped such that waste areas 60 are lifted off backing layer 56 as carrier lamination 24 passes over leading edge 32.
- Retaining bar 30 of delaminator 26 is positioned such that product areas 58 are prevented from being lifted up as carrier lamination 24 passes over separator edge 32. After passing through delaminator 26, waste areas 60 remain adhered to carrier web 14 by adhesive 72, and product areas 58 remain on backing layer 56 for later use as intended. The weeded laminates are collected in a pile, ready for use.
- Carrier web 14 with waste areas 60 remaining on it, is taken up by a carrier web take-up roller 34. When carrier web take-up roller 34 is full, it can be discarded and replaced with an empty roller.
- Carrier web 14 is preferably low-cost newsprint or the like.
- Fig. 1 illustrates two laminate sheets 50, the first one (to the left in Fig. 1 ) undergoing separation after adhering to carrier web 14 and the second one (to the right in Fig. 1 ) having adhesive applied to its waste areas.
- the laminate could be in the form of a continuous laminate web. In such case, after weeding the weeded web, with its product areas ready for use, would itself be wound onto a take-up roller.
- such laminate sheet (like that before it) has a waste area along its leading edge and illustrates adhesive having been applied to a leading edge portion of such waste area.
- adhesive is being applied all around the perimeter of product area 50.
- Fig. 6 serves to illustrate the application of adhesive only at leading portions of waste areas around product areas.
- Fig. 5 illustrates schematically a portion of another sheet-weeder apparatus 90 incorporating a carrier-surface member 80 which is in the form of an endless carrier web.
- Apparatus 90 also includes a separator edge 28 and a stripper 82.
- laminate sheet 50 and endless carrier web 80 move between a face layer laminator roller 18 and a backing layer laminator roller 20 to form a temporary carrier lamination 24.
- separator edge 28 of apparatus 90 facilitates the lifting of waste areas 60 from backing layer 56, leaving product areas 58 on backing layer 56 for later use as intended, while waste areas 60 remain adhered to endless carrier web 80.
- waste areas 60 which remain on endless carrier web 80 are removed from endless carrier web 80 by stripper 82, immediately freeing that portion of endless carrier web 80 for reuse.
- Stripper 82 incorporates a knife edge 86 which scrapes waste areas 60 from endless carrier web 80 and discards them into a waste bin 84.
- Alternative strippers can include apparatus which applies heat (or removes heat, i.e., makes cold) in order to soften (or harden) the adhesive and release, or at least facilitate release of, waste areas from the endless carrier web or other carrier-surface member.
- heat or removes heat, i.e., makes cold
- differing temperature levels may be used to accomplish the adhering or releasing of laminate layers.
- Alternatives for the waste bin can include, e.g., a take-up roller to collect continuous waste areas removed from the endless carrier web by the stripper or a chopper and a conveyor to discard large amounts of waste material.
- Precise application of adhesive to waste areas for sheet-weeding purposes depends on accurate information about the locations of product areas and waste areas. There are numerous ways in which such locations can be determined. Highly preferred ways involve the sensing of registration marks 44. For example, sensors can be in a line as is common in a computer scanner and either be fixed to a frame or free to move. Another alternative is that sensor 78 and applicator 76 can be moved independently to speed up operation of apparatus 10.
- the actuator apparatus can be designed to move the applicator(s) (and/or sensors) along three axes (rather just the two illustrated in Fig. 1 ) to give added flexibility and capability to the sheet-weeding apparatus.
- one preferred pattern involves application of adhesive on waste areas just beyond all of the edges of the product areas.
- Fig. 6 illustrates schematically a highly preferred location sensing and adhesive-application apparatus 92 having several sensing and adhesive-applicator units 94 arranged side by side in a line across laminate. Sensing/applicator units 94 need not move in order to sense the locations of registration marks 44 or to apply adhesive in the proper locations on the two laminate sheets 50 that are shown in Fig. 6 . Instead, based on their sensing and the rate of movement of laminate sheets 50, the adhesive applicators of sensing/applicator units 94 apply adhesive 72 at the proper time to be applied to discrete locations 62, which are the locations programmed to be appropriate to facilitate the later separating step. Fig. 6 also serves to illustrate the preferred application of adhesive on various selected leading edge portions 68 of the waste areas 60 of two discrete laminate sheets 50, as the laminate sheets pass sensing and adhesive-application apparatus 92.
- Fig. 7 illustrates another alternative adhesive-application apparatus 95, in this case an applicator which applies adhesive by direct contact with face layer 52 of laminate sheet 50.
- Adhesive application apparatus 95 applies adhesive 96 by means of an applicator roller 97 that has contact members 98 positioned to engage face layer 52 at the intended portions of its waste areas.
- Contact members 98 of applicator roller 97 receive adhesive 96 via transfer rollers 99, and deposit such adhesive upon contact with face layer 52.
- a variety of other adhesive applicator devices can be used in the apparatus of this invention.
- Fig. 8a and 8b illustrate an additional aspect of the inventive method wherein the leading edge of a waste area 60 is configured to facilitate more efficient and reliable removal of waste area 60 from the backing layer of the laminate. Waste area 60 surrounds product areas 58.
- a leading edge portion 110 of waste area 60 is substantially perpendicular to the weeding direction. As the separation process progresses along laminate sheet 50, the line of separation (not shown) reaches the leading edge 111 of leading edge portion 110, and a pulling force is applied to leading edge portion 110 through adhesive 72 (shown as deposited at a series of discrete locations across leading edge portion 110).
- leading edge 111 is perpendicular to the weeding direction, the total force required to cause separation suddenly increases as the line of separation reaches leading edge portion 110.
- the force ratio may be too high, thus preventing leading edge portion 110 from separating cleanly from the backing layer.
- Fig. 8b illustrates a preferred embodiment of the inventive method which lowers the force ratio, thereby enabling efficient and reliable separation of waste area from backing layer.
- the leading edge 113 of a leading edge portion 112 is given a slightly convex shape, thereby dividing leading edge 113 into a lead part 114 and two trailing lateral parts 116a and 116b. (The approximate width of parts 114, 116a, and 116b are indicated in Fig. 8b by the brackets drawn upstream of leading edge 113.)
- the line of separation reaches lead part 114 prior to reaching trailing lateral parts 116a and 116b.
- the length of the chord line across leading edge portion 112 gradually increases in length as the line of separation moves along sheet 50 in the weeding direction, thereby lowering the force ratio at the initiation of separation of waste area 60 and gradually raising the total force required to separate leading edge portion 112 from backing layer as the separation progresses.
- Fig. 8b also illustrates a highly preferred embodiment of leading edge portion 112.
- Starter tabs 100 (three shown), extending in a substantially upstream direction from lead part 114, are added to leading edge portion 112 along lead part 114 of leading edge 113. Starter tabs 100 lower the force required to initiate separation as the line of separation encounters leading edge portion 113, thereby further increasing the efficiency and reliability of the separation process.
- Fig. 9 illustrates another highly preferred embodiment of the inventive method.
- Sheet 50 is shown with waste area 60 and product areas 58a, 58b, 58c, and 58d, with each such product area having delicate leading edge portions 59a, 59b, 59c, and 59d respectively.
- Force-modifying slits 102a, 102b, 102c, and 102d surround delicate leading edge portions 59a, 59b, 59c, and 59d respectively.
- Fig. 10a and 10b provide enlarged views of product areas 58a and 58d respectively.
- Trailing edge portions 120 and 122 are adjacent to delicate leading edge portions 59a and 59d respectively, with trailing edge portions 120 and 122 having force-modifying slits 102a and 102d respectively.
- slit 102a is positioned such that the end points 104a and 104b of slit 102a are on opposite sides of delicate leading edge portion 59a.
- slit 102a allows trailing edge portion 120 to temporarily remain on the backing layer until the line of separation progresses to end points 104a and 104b.
- the force ratio for delicate leading edge portion 59a is high enough to cause separation of trailing edge portion 120 from the backing layer without causing delicate leading edge portion 59a to be separated from the backing layer.
- Fig. 10b illustrates delicate leading edge portion 59d, having an even sharper point than delicate leading portion 59a.
- end points 106a and 106b of slit 102d are comparatively farther downstream than endpoints 104a and 104b, thus accommodating the increased sharpness of delicate leading edge portion 59d.
- Fig. 11 illustrates another embodiment of the inventive method in which a temporary product area surrounds a particularly delicate product area.
- Sheet 50 is shown with waste area 60 surrounding a temporary product area 132 which surrounds a particularly delicate product area 130.
- temporary product area 132 is not separated from the backing layer by the automatic weeding process but is removed by manual weeding after the completion of the automatic weeding process.
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- Forests & Forestry (AREA)
- Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
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Claims (25)
- Procédé pour retirer au moins une zone de rebut (60) d'une couche de face (52) d'un stratifié (50) composé d'une couche de support (56), la couche de face (52) adhérant à la couche de support (56) de manière amovible pour laisser au moins une zone de produit (58) de la couche de face (52) en place sur la couche de support (56),
le procédé comprenant les étapes suivantes :premièrement, appliquer un adhésif (72) sur des portions de la (des) zone(s) de rebut (60) à des emplacements discrets (62) ;deuxièmement, faire temporairement adhérer le stratifié (50) à une surface porteuse (14, 80) en utilisant l'adhésif (72) ; ettroisièmement, séparer le stratifié (50) de la surface porteuse (14, 80), la (les) zone(s) de rebut (60) restant sur la surface porteuse (14, 80). - Procédé selon la revendication 1, dans lequel la surface porteuse est la surface d'une feuille porteuse (14, 80).
- Procédé selon la revendication 2, dans lequel l'étape de séparation comprend de décoller la feuille porteuse (14, 80) du stratifié (50).
- Procédé selon la revendication 3, dans lequel l'étape de séparation inclut de tirer la structure stratifiée porteuse (14, 80) au-dessus d'un bord séparateur (28) amorçant ainsi une séparation du stratifié (50) de la feuille porteuse (14, 80).
- Procédé selon la revendication 2, dans lequel la feuille porteuse est une bande porteuse (14, 80).
- Procédé selon la revendication 5, dans lequel le stratifié est une feuille stratifiée discrète (50) et le procédé comprend en outre
dérouler une portion d'une bande porteuse (14, 80) d'un rouleau (16) ;
mettre en oeuvre la stratification de la feuille stratifiée discrète (50) sur la bande de support (14, 80) sur la portion déroulée de celle-ci ;
mettre en oeuvre l'étape de séparation sur la portion déroulée ; et
après cela enrouler la bande porteuse (14, 80) avec la (les) zone(s) de rebut (60) sur celle-ci. - Procédé selon la revendication 6, dans lequel la bande porteuse (14, 80) se déplace dans une direction le long de sa longueur au moins pendant les étapes de stratification et de séparation.
- Procédé selon la revendication 7, dans lequel le produit et la (les) zone(s) de rebut (58, 60) ont chacun au moins une portion de bord d'attaque (64, 68) et au moins une portion de bord de fuite (70, 66), certaines des portions de bord d'attaque (68) de la (des) zone(s) de rebut (60) étant adjacentes à des portions de bord de fuite (70) des zones de produit (58), et dans lequel l'étape d'application comprend d'appliquer un adhésif (72) sur la (les) portions de bord d'attaque (68) des zones de rebut (60).
- Procédé selon les revendications 1, 2 ou 5, dans lequel l'adhésif (72) est appliqué au voisinage de la (des) zone(s) de produit (58).
- Procédé selon les revendications 1, 2 ou 5, dans lequel l'adhésif (72) est un liquide à séchage rapide et l'application s'effectue en projetant l'adhésif sans contact applicateur avec les zones de rebut (60).
- Procédé selon les revendications 1, 2 ou 5, dans lequel l'étape d'application est commandée par ordinateur.
- Procédé selon les revendications 1, 2 ou 5, dans lequel
la séparation progresse le long d'une direction de pré-retrait ;
une zone de rebut (60) a une portion de bord d'attaque (112), un bord d'attaque (113) ayant une partie d'attaque (114) et au moins une partie latérale de fuite (116) ;
l'étape de séparation inclut de séparer la zone de rebut (60), avec la feuille porteuse (14, 80), de la couche de support (56) le long de la partie d'attaque (114) avant que la (les) partie(s) latérale(s) de fuite (116) soit (soient) séparée(s) de la couche de support (56), créant ainsi une ligne de corde couvrant la partie d'attaque (114) ;
la poursuite de l'étape de séparation jusqu'à ce que la ligne de corde couvre sensiblement la portion de bord d'attaque (110) ;
et ensuite l'achèvement de l'étape de séparation. - Procédé selon la revendication 12, dans lequel la portion de bord d'attaque (112) a au moins une languette d'amorce (110) le long de la partie d'attaque (114) du bord d'attaque (113), la languette d'amorce (100) s'étendant dans la direction opposée à la direction de pré-retrait et ayant une largeur inférieure à environ 10 % de la largeur de la portion de bord d'attaque (112).
- Procédé selon la revendication 12, dans lequel le bord d'attaque (113) a deux parties latérales (116a et 116b), une sur chaque côté de la partie d'attaque (114).
- Procédé selon la revendication 14, dans lequel le bord d'attaque (113) est convexe.
- Procédé selon la revendication 15, dans lequel le bord d'attaque (113) est un arc sensiblement circulaire ayant un rayon supérieur à la moitié de la largeur de la portion de bord d'attaque (112).
- Procédé selon les revendications 1, 2 ou 5, dans lequel
la séparation progresse le long d'une direction de pré-retrait de positions amont à des positions aval ;
la zone de produit a une portion de bord d'attaque délicate (59) ; et
la zone de rebut (60) inclut une portion de bord de fuite (120, 122) adjacente à la portion de bord d'attaque délicate (59), la portion de bord de fuite (120, 122) ayant une fente de modification de force (102) dans celle-ci qui entoure la portion de bord d'attaque délicate (59) et a des extrémités (104) sur des côtés opposés de celle-ci. - Procédé selon les revendications 1, 2 ou 5, dans lequel au moins une zone de produit (130) est entourée par une zone de produit temporaire (132) qui n'est pas séparée de la zone de support.
- Procédé selon la revendication 1, comprenant en outre de retirer ultérieurement la (les) zone(s) de rebut (60) de la surface porteuse (14, 80) et de mettre celle(s)-ci au rebut.
- Dispositif (10, 90) pour retirer au moins une zone de rebut (60) d'une couche de face (52) d'un stratifié (50) composé d'une couche de support (56), la couche de face (52) adhérant à celle-ci de manière amovible, pour laisser au moins une zone de produit (58) de la couche de face (52) en place sur la couche de support (56),
comprenant :un support (12) pour le stratifié (50) ;un applicateur d'adhésif (76) monté au voisinage du stratifié supporté (50) ;un actionneur (36) associé à l'applicateur (76) ;une commande (46) pour faire appliquer par l'actionneur (36) un adhésif (72) sur la (les) zone(s) de déchet (60) à des emplacements discrets (62) ;un élément de surface porteuse (14, 80) ayant une surface porteuse positionnée pour recevoir le stratifié (50) avec le stratifié (50) adhérant à celle-ci ; etun séparateur (28) au voisinage de la surface porteuse (12) pour séparer le stratifié (50) de la surface porteuse (14, 80) avec la (les) zone(s) de rebut (60) restant sur la surface porteuse (14, 80). - Dispositif selon la revendication 20, dans lequel l'élément de surface porteuse (14, 80) est une feuille porteuse.
- Dispositif selon la revendication 21, dans lequel la feuille porteuse est une bande porteuse (14, 80).
- Dispositif selon la revendication 22, dans lequel le séparateur (28) inclut un bord séparateur (32) positionné pour un passage de la bande de support au-dessus de celui-ci en tension, pour ainsi amorcer une séparation du stratifié (50) de la bande porteuse (14, 80).
- Dispositif selon les revendications 20, 21 ou 22, dans lequel le produit et la (les) zone(s) de rebut (58, 60) ont chacun au moins une portion de bord d'attaque (64, 68) et au moins une portion de fuite (70, 66), certaines des portions de bord d'attaque (68) de la (des) zone(s) de rebut (60) étant adjacentes à des portions de bord de fuite (70) des zones de produit (58), et dans lequel la commande (46) est programmée par ordinateur pour appliquer un adhésif (72) sur la (les) portion(s) de bord d'attaque (68) des zones de rebut (60).
- Dispositif selon les revendications 20, 21 ou 22, dans lequel la couche de face (52) du stratifié (50) a une pluralité de marques de concordance (44) sur la (des) zone(s) de produit (58) et autour de celles-ci et dans lequel
la commande (46) est programmée par ordinateur avec des informations sur la (les) zone(s) de produit (58) et la (les) zone(s) de rebut (60) ; et
un capteur (78) capable de détecter des emplacements des marques de concordance (44) et de transmettre ces informations à l'ordinateur est monté au voisinage de la surface de travail (12),
de sorte que l'applicateur (76) est actionné en réponse à (a) des emplacements des marques de concordances (44) détectés par le capteur (78) et (b) des informations sur la (les) zone(s) de produit (58) et la (les) zone(s) de rebut (60).
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US10/094,691 US6797103B2 (en) | 2001-03-12 | 2002-03-11 | Automatic waste-area removal method and apparatus |
PCT/US2002/007318 WO2002072351A1 (fr) | 2001-03-12 | 2002-03-12 | Procede et appareil automatique d'elimination de zones dechets |
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EP1390201A4 EP1390201A4 (fr) | 2008-08-20 |
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2002
- 2002-03-11 US US10/094,691 patent/US6797103B2/en not_active Expired - Lifetime
- 2002-03-12 WO PCT/US2002/007318 patent/WO2002072351A1/fr not_active Application Discontinuation
- 2002-03-12 AT AT02750598T patent/ATE510691T1/de not_active IP Right Cessation
- 2002-03-12 CA CA002478070A patent/CA2478070A1/fr not_active Abandoned
- 2002-03-12 EP EP02750598A patent/EP1390201B1/fr not_active Expired - Lifetime
-
2004
- 2004-08-23 US US10/923,935 patent/US7416008B2/en not_active Expired - Lifetime
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102016106922A1 (de) * | 2016-04-14 | 2017-10-19 | M & R Beteiligungsgesellschaft mbH | Vorrichtung und Verfahren zur Bearbeitung einer Folie |
Also Published As
Publication number | Publication date |
---|---|
US20050087306A1 (en) | 2005-04-28 |
US7416008B2 (en) | 2008-08-26 |
WO2002072351A1 (fr) | 2002-09-19 |
CA2478070A1 (fr) | 2002-09-19 |
EP1390201A4 (fr) | 2008-08-20 |
US20020124948A1 (en) | 2002-09-12 |
EP1390201A1 (fr) | 2004-02-25 |
ATE510691T1 (de) | 2011-06-15 |
US6797103B2 (en) | 2004-09-28 |
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